1. Introduction
In the past 48 hours, a surge in sustainable building practices has spotlighted metal clad exteriors as a top choice for eco-conscious construction. With rising demand for durable, low-maintenance, and recyclable building materials, architects and builders are increasingly specifying metal clad wall systems, corten steel facades, and zinc clad roofs for both residential and commercial projects. This guide provides a comprehensive, step-by-step approach to installing and maintaining these systems effectively.
Metal clad—often referred to as metalclad—encompasses a wide range of applications, from metal clad siding and metal clad roofs to specialized components like pac clad column covers and pac clad coping. Understanding the clad metal meaning is essential: it refers to composite materials where a base metal (like steel or aluminum) is bonded with a corrosion-resistant outer layer such as zinc, copper, or stainless steel.
2. Choosing the Right Metal Clad Type
Selecting the appropriate metal clad type depends on climate, budget, and design goals. Common options include:
- Corten steel siding for rustic, weathering aesthetics (note: corten siding cost varies by region and thickness)
- Zinc metal siding or zinc facade for sleek, modern looks with natural patina development
- Aluminum clad steel or aluminum clad sheet for lightweight, corrosion-resistant performance
- Colorbond standing seam or vertical standing seam metal siding for clean lines and superior water shedding
- Copper siding or titanium clad for premium, long-lasting finishes
For industrial or utility applications, consider aluminum clad pipe insulation or metal clad electrical wire, which offer thermal and mechanical protection.
3. Preparing for Installation
Before installing any metal clad system, ensure your substrate is structurally sound, level, and properly insulated. Use metal clad insulation behind walls or under roofs to enhance energy efficiency. Always verify local building codes—especially when using metal clad wire in commercial buildings in Pennsylvania or similar jurisdictions.
Gather necessary tools: metal snips, drill with metal bits, measuring tape, chalk line, safety gear, and compatible fasteners. For corrugated steel facade or exterior corrugated metal siding, use neoprene-washed screws to prevent leaks.
4. Installing Metal Clad Walls and Facades
4.1. Wall Substrate and Moisture Barrier
Install a high-quality weather-resistive barrier (WRB) over sheathing. This is critical for metal clad wall systems to manage condensation and airflow.
4.2. Mounting Furring Strips
Attach horizontal or vertical furring strips (typically aluminum or treated wood) to create an air gap. This promotes drainage and drying behind the cladding.
4.3. Panel Installation
Begin at the bottom corner and work upward. For standing seam facade systems like pac clad hwp or pac clad standing seam roof panels, interlock seams precisely. For corrugated profiles, overlap panels according to manufacturer specs—usually 1–2 corrugations.
Use concealed fasteners for standing seam systems to maintain clean aesthetics and reduce thermal bridging. For exposed-fastener systems like metal weatherboard, pre-drill holes to avoid warping thin-gauge sheets.
5. Installing Metal Clad Roofs
Metal clad roofs—such as zinc clad roof, colorbond standing seam, or pac clad standing seam—require precise slope and underlayment. Minimum roof pitch is typically 3:12 for standing seam.
Start at the eave and secure starter strips. Align panels carefully; misalignment can cause leaks or visual distortion. Install pac clad coping along parapets and pac clad column covers for architectural continuity.
Ensure all penetrations (vents, chimneys) are flashed with compatible metal (e.g., stainless steel plate or aluminum diamond tread plate) to prevent water intrusion.
6. Maintenance and Troubleshooting
6.1. Cleaning
Clean metal clad surfaces annually with mild soap and water. Avoid abrasive cleaners that can damage coatings on aluminum clad stainless steel or stainless clad aluminum panels.
6.2. Rust and Corrosion
Inspect for scratches or chips, especially on steel plate or mild steel plate substrates. Touch up with matching paint or protective coating. Corten steel plate develops a stable rust layer but should not be used in high-salt or high-humidity zones without consultation.
6.3. Fastener Issues
Loose or corroded fasteners are common in older installations. Replace with stainless steel or coated variants rated for exterior use.
7. Common Mistakes to Avoid
- Skipping the air gap behind metal clad siding, leading to moisture trapping
- Using incompatible metals (e.g., copper near aluminum) causing galvanic corrosion
- Over-tightening fasteners, which can deform panels or compromise seals
- Ignoring thermal expansion—leave adequate room for movement in long runs of aluminum clad sheet or zinc metal siding
8. Conclusion
Metal clad exteriors offer unmatched durability, design flexibility, and sustainability when installed and maintained correctly. Whether you’re building a steel clad house, retrofitting a metal clad shed, or specifying a corten steel facade for a commercial project, following these steps ensures long-term performance and visual appeal. Always source quality materials—such as 6061 T6 aluminum plate, 316 stainless steel plate, or ASTM A387 alloy plate—from reputable distributors to guarantee compatibility and longevity.
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